Composite yarn forming method and apparatus

ABSTRACT

A three component composite yarn is produced in the following manner: A CARRIER STRAND UNDER TENSION, A TACKY POLYMER AND STAPLE FIBERS ARE INTRODUCED INTO A GROOVE OF A ROTATING, CIRCUMFERENTIALLY GROOVED ROLL; A TWIST IS IMPARTED TO THE THREE COMPONENTS WITHIN THE GROOVE OF THE ROLL; THE TACKY POLYMER COMPONENT IS COOLED AND COAGULATED; AND THE OBTAINED YARN IS CONTINUOUSLY AND LINEARLY WOUND UP ON A COLLECTING ROLL. The apparatus for achieving these results basically comprises a rotatable circumferentially grooved roll; means for simultaneously introducing into the groove of said roll the three components mentioned above; tension control means controlling the supply of the carrier strand before it is directed into the groove of the roll; a false twist type spindle following the grooved roll through which the yarn coming out of the groove is passed and by which it is twisted, this spindle being positioned with respect to the grooved roll such as to impart tension and force the strand within the groove against the bottom of the groove; a pulling roll following the spindle to maintain the yarn under positive pull; and wind-up arrangement for linearly winding the obtained spun yarn on a collecting roll.

Elite tates atet [191 Bobkowicz et al.

[ COMPOSITE YARN FORMING METHOD AND APPTUS [76] Inventors: Emilian Bobkowicz; Andrew John Bobkowicz; Margaret Mary Lefebvre, Nee Bobkowiez, all of 1435 St. Alexander St., Room 310, Montreal, Quebec, Canada [22] Filed: Oct. 2, 1972 [21] Appl. No.: 294,103

[44] Published under the Trial Voluntary Protest Program on January 28, 1975 as document no. B 294,103.

[30] Foreign Application Priority Data July 6, 1972 Canada 146543 [52] US. Cl. 57/35; 57/34 HS; 57/50; 57/5895; 57/156; 57/164; 264/103 [51] Int. Cl. ..D01H 13/30; DOll-l 1/12 [58] Field of Search 57/34 R, 34 HS, 35, 50, 57/58.89-58.95, 156, 157, 164; 264/103 [56] References Cited UNITED STATES PATENTS 2,289,568 7/1942 Bloch 57/34 R 2,743,572 5/1956 Hiensch... 57/34 HS 3,445,993 5/1969 Vorisek 57/5895 X 3,494,118 2/1970 Bobkowicz et a]. 57/35 3,548,581 12/1970 Bobkowicz et al. 57/35 X Primary Examiner-lohn Petrakes Attorney, Agent, or Firm-Stevens, Davis, Miller & Mosher [57] STRACT A three component composite yarn is produced in the following manner:

a carrier strand under tension, a tacky polymer and staple fibers are introduced into a groove of a rotating, circumferentially grooved roll;

a twist is imparted to the three components within the groove of the roll;

the tacky polymer component is cooled and coagulated; and

the obtained yarn is continuously and linearly wound up on a collecting roll.

The apparatus for achieving these results basically comprises a rotatable circumferentially grooved roll; means for simultaneously introducing into the groove of said roll the three components mentioned above;

tension control means controlling the supply of the carrier strand before it is directed into the groove of the roll; a false twist type spindle following the grooved roll through which the yarn coming out of the groove is passed and by which it is twisted, this spindle being positioned with respect to the grooved roll such as to impart tension and force the strand within the groove against the bottom of the groove; a pulling roll following the spindle to maintain the yarn under positive pull; and wind-up arrangement for linearly winding the obtained spun yam on a collecting roll.

14 Claims, 2 Drawing Figures I US. Patent I D'ec.91975 Sheet 1 of2 3,924,39 v

FIG,1

US. Patent Dec. 9 1975 Sheet2 of2 3,924,396

COMPOSITE YARN FORMING NEETHOD AND APPARATUS This invention relates -to an improved and simplified system of composite yarn production. More particularly the invention relates to a method and apparatus for producing yarn from three components, namely a carrier strand, a tacky or plastic polymer substrate and staple fibers.

In U.S. Pat. No. 3,548,581 of Dec. 22, 1970, there is described a method and an apparatus for the manufacture of fibertapes by introducing staple fibers and a tacky polymer substrate between a pair of rotating pressure rolls having continuous circumferential grooves and positioned face to face so that each male member of the grooved surface of one roll fits into the corresponding female member of the other roll to form at the nip point of said rolls cavities within which the fibertapes are produced.

However, in order to produce yarn, such fibertapes must be twisted using conventional ring devices or a ringless spinning system such as that described and claimed in U.S. Pat. No. 3,548,581 of Dec. 22, 1970, where a pair of circumferentially grooved consolidating rolls is again employed to form the fibertapes prior to passage of the same in a heating fiber restrictive zone where the tapes are twisted from below to form yarn.

It has now been surprisingly found that in the case of three component yarn production, the intermediate step of forming fibertapes can be entirely eliminated and, in addition, the heating fiber restrictive zone can also be eliminated; thus the composite three component yarn can be produced directly by ringless spinning Without even using a pair of consolidating pressure rolls. Indeed, it has now been found that the desired result can be achieved with only one circumferentially grooved roll and a proper arrangement of the spindle and other elements. Furthermore it has been made possible in a preferred embodiment of this invention to combine the licker-in fiber feed means and the circumferentially grooved yarn formation roll into one unit.

This unexpected result makes it possible to produce three component yarn in an extremely simple manner, using a very simple and efficient system for that purpose.

Basically the novel method of producing composite spun yarn in accordance with the present invention comprises:

forwarding a carrier strand under tension into a groove of a rotating circumferential grooved roll and simultaneously introducing into said groove staple fibers and a polymer in tacky condition;

imparting to the three components within the groove,

namely carrier strand, tacky polymer and staple fibers, a predetermined twist from an angle such that the carrier strand in the groove is forced against the bottom of said groove while being twisted with the other components of the yarn within said groove;

cooling to coagulate the polymer component of the twisted yarn; and

linearly and continuously winding up the obtained twisted yarn on a collecting roll.

Preferably, in accordance with the present invention, the twist is imparted by means of a false twist type spindle positioned following the grooved roll. The yarn travels from the grooved roll to and through the spindle at any preferred angle whereby a twist is imparted which travels back to the groove of the roll where the three components are twisted, transformed and consolidated into spun yarn while being forced against the bottom of the groove.

The grooved roll may be perforated and the fibers held within the groove by suction from within the roll.

In addition, to improve fiber lay and accelerate the cooling action of the polymer, a jet of air may be directed into the groove at the point where yarn is exiting therefrom. This is an optional but preferential embodiment of the invention. Furthermore, the grooved roll may, on one or both sides of the groove, be provided with a predetermined number of teeth, pins or needles mounted circumferentially and helically to form a V shaped helical arrangement converging towards the center, which performs the function of opening up, collecting and carrying the individual staple fibers from two separate strand feed-in positions towards the cen ter groove of the roll where they are brought into contact with the plastic polymer surface of the carrier before twisting.

The fiber opening needles projecting outwardly on the sides of the groove of the roll may also be supplemented by small cutting blades which are mounted in staggered arrangement between such needles and which enable the feed-in of continuous filament tow and conversion of the latter during the feed-in into staple fibers which are then introduced into the groove of the roll. Similarly an oriented narrow thin polymer tape can be fibrillated and cut into staple fibers suitable to form a composite spun yarn. This is an optional but preferred embodiment of the invention.

The apparatus in accordance with this invention for producing composite spun yarn will comprise:

a rotatable circumferentially grooved roll;

means for simultaneously introducing into the groove of said roll three components, namely staple fibers, a carrier strand and a tacky polymer;

tension control means through which said carrier strand passes before being directed into the groove of said roll;

a spindle following said grooved roll through which the composite material coming out of the groove is passed, said spindle imparting twist to said composite material which twist is transmitted back into the groove where the three components are thus twisted and consolidated into said spun yarn, said spindle being positioned with respect to said grooved roll such as to impart tension and force the filament within the groove against the bottom of said groove;

at least one pulling device following said spindle to maintain the yarn under positive pull;

and a wind-up arrangement for linearly winding the obtained spun yarn on a collecting roll.

The means for introducing the tacky polymer into the groove of the roll preferably comprise an extruder above the groove from which the tacky polymer is directly extruded into said groove. The means for introducing the carrier strand are preferably adapted to direct said carrier strand through said extruder and into the groove of said grooved roll together with the tacky polymer which thereby coats said carrier strand with a tacky layer of the polymer.

The means for introducing the staple fibers preferably comprise licker-in fiber delivery means by which the fibers are opened and directed into the groove of the grooved roll. Alternatively the circumferential grooved roll may comprise on one or both sides of said groove a plurality of outwardly projecting needles following a helical circumferential path which converges towards said groove to bring continuously the combed out fibers from the fiber feed-in means into contact with the carrier and polymer in said groove for consolidation and transformation by twist into a composite spunyarn.

In addition, the grooved roll may have perforations leading from the bottom of the groove towards the inside of the roll and suction means may be provided within the grooved roll to' produce suction in the groove from within the roll to aid the collection of the fibers in the groove and to achieve proper control of the fibers during the twisting, thereby counteracting the centrifugal forces produced during high speed operations.

Finally, according to another preferred embodiment of the invention means may be provided for directing a jet of air against the yarn exiting from the groove of the grooved roll.

It should, of course, be understood that instead of one groove, several grooves may be provided within a single roll or a plurality of narrow rolls may be used each with one groove and mounted axially side by side. Thereby a machine is formed for producing several composite yarns at the same time. This will be obvious to any man familiar with the relevant art.

Two preferred but non limitative embodiments of the present invention will now be described with reference to the appended drawings in which:

FIG. 1 represents an elevation, partly sectional view of one embodiment of the apparatus suitable for carrying out the method of the present invention, with sections AA showing two different types of the groove, with and without perforations; and

FIG. 2 is an elevation view of another preferred embodiment of the apparatus of this invention wherein the rolls are provided with outwardly projecting needles, with section B-B showing the arrangement of the perforated groove in such embodiment.

According to the embodiment illustrated in FIG. 1, there is provided a rotatable circumferentially grooved roll 1, the groove of which is preferably pointed as shown in sections A-A and may also be provided with perforations 3 leading towards the inside .of said roll 1. In the inside there may also be provided a suction device (not shown) for producing suction within the perforated circumferential groove of roll 1. An extruder 3 is mounted just above the groove of the circumferential roll 1 for extruding a tacky polymer, introduced by inlet 4 into said extruder. At the same time, a carrier strand 5 is unwound from bobbin 6 and is directed by means of carrier tension control rollers 7 and 8 into and through extruder 3. This arrangement enables for carrier strand 5 to be coated with the tacky polymer substrate extruded from extruder 3 and to be directed in such condition into the circumferential groove of roll 1. Licker-in device 9 is used to supply staple fibers into the groove of roll 1 and suction from within the roll imparted through perforations 2 will facilitate holding of these fibers against the groove, when such perforations and suction are provided. The staple fibers are combed out of the supply material 10, which may be in the form of webs, slivers or other arrangements, by means of the licker-in rollers provided in the licker-in device 9. Air blowing means 11 may be mounted within one of these rollers for blowing the staple fibers out of the licker-in device and into the groove of roll 1.

Then, following roll 1, there is arranged, at an appropriate angle with respect to said roll 1, a twist imparting spindle 12 of the false twist type which, in this case is a false twist friction type spindle. Yarn 15 passing through said spindle is imparted with desired twist which is transmitted towards portion 14 of the circumferential groove within the grooved roll 1 where the actual twisting and formation of the yarn takes place. The arrangement of spindle 12 is such that usually it will keep yarn 15 at an acute angle with respect to the horizontal and thereby will hold it under tension and will pull against the bottom of the groove, carrier strand 5 coated with the tacky polymer substrate and surrounded by the staple fibers at the point where the yarn is twisted and formed within the groove, which is approximately point 14 shown on the drawing.

Then, a yarn pulling and advancing roll 16 is provided following spindle 12 which imparts positive pull and tension to the yarn. Instead of one roll 16 a pair of nip rollers such as rollers 7 and 8 or standard multiple wrap advancing rolls can be used for this purpose. Finally, a wind-up arrangement 17 is provided for winding up the obtained yarn directly on collecting roll 18.

The operation of this arrangement'is as follows: the carrier strand 5 is removed from bobbin or carrier supply 6 and is forwarded by carrier strand tension control rolls 7 and 8 under tension into and through the middle of extruder 3. A suitable polymer is also introduced into said extruder through opening 4 and is extruded therefrom in such a way as to coat carrier strand 5 which passes through said extruder and into the groove of circumferentially grooved roll 1. At the same time, a control quantity of staple fibers is forwarded into the grooved roll 1 by licker-in fiber delivery device 9 and also introduced into the groove of the same roll 1. These fibers may be retained within the groove by means of suction means (not shown) within roll 1 if the groove is provided with perforations 2. The fibers are combed out and forwarded by the licker-in device 9 from any desired fiber supply 10 such as tape, web, sliver, roving, tow and the like, of any suitable form. These are opened within the licker-in device and then delivered into the groove of roll 1 by blowing means 1 l.

The above components are twisted within the groove approximately at point 14 by false twist spindle 12 which is positioned following roll 1 at an appropriate angle and from which the twist is transmitted through already formed yarn 15 to point 14 within the groove of the roll. At point 14 the three components of the yarn are firmly held against the bottom of the groove by tension and it is important that spindle l2 and control rollers 7 and 8 provide good tension to achieve twisting at point 14.

Thereafter, the obtained yarn 15 is pulled and advanced by suitable roller 16 and is wound by wind-up device 17 on collecting roll 18 in a continuous and linear fashion. Between point 14 and spindle 12 the yarn is also cooled to coagulate the tacky polymer.

As shown in sections A-A the groove of roll 1 is preferably of a triangular or pointed shape. According to a further embodiment of this invention there is provided an optional but preferred feature of positioning an air jet 20 which directs air under pressure on yarn 15 just as it exits the groove of roll 1. This air helps in fiber consolidation and improves lay. It also provides a more rapid cooling and coagulation of the tacky polymer within the formed yarn 15.

In respect of the alternative arrangement shown in FIG. 2, the fiber supply is directly fed by supply arrangement 19 onto the surface of grooved roll 21 provided with outwardly projecting needles 22 mounted in a converging, circumferential'helical path 24 on both sides of groove 23. The fiber supply 10 may thus be fed from one or two sources of fibrous material onto the needled surface of the roll 21 onto one or both sides of the groove 23. The fibers from this supply 10 will be combed out by the needled arrangement and will be continuously conveyed towards and into the central groove 23 due to the converging circumferential helical out fibers by needles 22 to the grooved center 23 of the roll 21.

The following examples are intended to provide further illustration of the present invention:

Many runs have been effected for producing yarn with the process and'apparatus described above. Five examples of such runs in which various specific components have been employed to produce desired yarn properties at predetermined machine settings are summarized in the table on the following page. These examples clearly show that three component yarns can be produced in accordance with the present invention having desirable composition and other properties, in a simple and efficient manner.

TABLE OF EXAMPLE YARN CONSTRUCTIONS AND MACHINE SETTINGS TO ACHIEVE THEM MATERIALS USED YARN PROPERTIES MACHINE SETTINGS Ex. Fibers Carrier Resin Count Tenacity Composition Fiber Grooved Twist No. (F) (C)) (R) (tex) (gJtex) (F/C/R Feed Roll Speed Applied (ft/min) (ft/min) (t.p.i.)

l. Polypro. 2.5" Polypro- Polyethylene 179 10.1 34/22/44 4.9 330 22 Sliver 4134 tex pylene 150 MI. dpf ribbon Melt T.

40 tex 300F 2. Cotton 15/16" Glass Polyethylene 1 14 15.6 27/28/45 2.1 300 54 Sliver tex 4440 Multifil. 150 Ml.

33 tex Melt T.

350"? g 3. Polyester 1 Polyester Polyester 72 12.1 37/21/42 9.3 1400 74 Sliver 4000 tex Multifil. i.v. 0.70 1.5 dpf l5 tex Melt T.

345F I 4. Polyester/Cotton Polyester Polyethylene 46 l 1.5 45/25/30 7.3 2000 40 Waste Multifil. 150 M.I. Random web 4400 tex l5 tex Melt T. 1.5 dpf 350F 5. Rayon 1 9/16" Nylon Polyethylene 46 10.8 34/23/43 21.3 4100 43 Sliver 3015 tex Multifil. 150 MI. 1.5 dpf ll tex Melt T.

path of the needles. The fibers will then be drawn into the groove 23 by air suction from within and brought into contact with the carrier strand coated with the tacky polymer which is also introduced into said groove from extruder 3.

There may also be provided a central pressure roll 26 the purpose of which is to restrain the fibers deposited into the groove 23. This pressure roll 26 may also have a circumferential groove in the middle thereof so as to prevent contact with the tacky polymer coated on the carrier strand before said polymer is consolidated with the staple fibers. Thus pressure roll 26 generally serves to provide tension to the strand to enhance the consoli dation and formation of the spun yarn 1.5 while twisting torque is applied by spindle 12.

Thus, the alternative embodiment shown in FlG. 2 provides for a combined licker-in and consolidation roll 21 wherein the licker-in effect is achieved by the special arrangement of needles 22. One or both sides of the needled licker-in roll 21 may also be provided with outwardly protruding cutting blades 27. These small blades of a razor blade type are mounted between the needles in a staggered arrangement and are intended to cut the fiber supply 110 which it is introduced in. the form of a continuous filament tow or the like for conversion into staple fibers.

An enlarged top section view of this combined lickerin and consolidation roll 21 is shown in cross-section B-l3 together with the protective cover which ensures safe and adequate transportation of the combed The above examples are, however, non limitative in nature and it will be appreciated that many variations in the components, yarn properties and machine settings can be made without departing from the scope of the present invention. Thus, fibers can be supplied in staple and carrier filament form. Staple fibers of any preferred nature or type can be used. Also, any ready carrier strand in filament, ribbon or other form can be employed and also any extrudable resin that will produce desirable properties within the yarn can be utilized. Thus, the nature of fibers, carrier, and resin and their proportions will greatly depend on the final yarn properties that one wishes to obtain and these, of course, will depend on the requirements of each ultimate user of the yarn. Machine settings will generally be similar, although variations may be made depending on the desired speed of operation and also on properties of the components employed. Similarly, the apparatus arrangements are not limitative. Thus instead of rollers being used to control carrier strand tension, disk or gate type devices may be employed, as can any other suitable arrangement evident to any man familiar with the art. Also the false twister may be varied to the offcenter crank or pin types as well as other alternatives known in the art.

We claim:

ll. Method of producing composite spun yarn which comprises: forwarding a carrier strand under tension into a groove of a rotating circumferentially grooved roll; simultaneously introducing into said groove a polymer in tacky condition and also introducing thereinto staple fibers; imparting to the three components within the groove, namely carrier strand, tacky polymer and staple fibers, a predetermined twist from an angle such that the strand in the groove is forced against the bottom of said groove while being twisted with the other components of the yarn within said groove; cooling to coagulate the polymer component of the twisted yarn; and linearly and continuously winding up the obtained twisted yarn on a collecting roll.

2. Method according to claim 1, in which the twist is imparted by means of a false twist type spindle positioned following said groove roll roll; the yarn travelling from the grooved roll to and through said spindle at an acute angle with respect to the horizontal is thereby imparted with twist which travels back to the groove of the roll where the three components are twisted and transformed into spun yarn while being forced against the bottom of the groove.

3. Method according to claim 1, in which the grooved roll is perforated and the fibers are held within the groove by suction from within the roll.

4. Method according to claim 1, further comprising directing a jet of air into the groove substantially at a point where yarn is exiting therefrom.

5. Apparatus for producing composite spun yarn which comprises: a rotatable circumferentially grooved roll; means for simultaneously introducing into the groove of said roll three components, namely a carrier strand, a tacky polymer and staple fibers; tension control means through which said carrier filament passes before being directed into the groove of said roll; a spindle following said grooved roll through which the yarn coming out of the groove is passed, said spindle imparting a twist to said yarn which is transmitted back into the groove where the three components are thus twisted into spun yarn, said spindle being positioned at an angle with respect to said grooved roll such as to impart tension and force the strand in the groove against the bottom of said groove; at least one pulling device following said spindle to maintain the yarn under positive pull; and a wind-up arrangement for linearly winding the obtained composite spun yarn on a collecting roll.

6. Apparatus according to claim 5, wherein the means for introducing the tacky polymer comprise an extruder above the groove of said grooved roll from which the tacky polymer is extruded into said groove.

7. Apparatus according to claim 6, wherein said means for introducing the carrier strand are adapted to direct said filament through said extruder and into the groove of said grooved roll together with the tacky polymer which is thereby coated on said strand.

8. Apparatus according to claim 5, wherein the means for introducing the'staple fibers comprise lickerin fiber delivery means by which the fibers are opened and directed into the groove of the grooved roll.

9. Apparatus according to claim 5, wherein the grooved roll has perforations leading from the bottom of the groove towards the inside of the roll and suction means are provided within said grooved roll to produce suction in said groove from within the roll.

10. Apparatus according to claim 5, further comprising means for directing a jet of air against the yarn exiting from the groove of said grooved roll.

11. Apparatus according to claim 5, wherein said roll has outwardly projecting needles on at least one side of the groove, which are arranged in a converging helical circumferential path on the roll surface, said needles combing out the fibers from a direct fiber supply and conveying them into the groove of the roll.

12. Apparatus according to claim 11, further comprising cutting blades mounted on the roll in staggered arrangement between the needles.

13. Apparatus according to claim 11, further comprising a pressure roller mounted for pressurizing rotational movement against the groove of said roll, said roller restraining the fibers within the groove substantially without pressing the tacky polymer component.

14. Apparatus according to claim 5, further comprising a pressure roller mounted for pressurizing rotational movement against the groove of said roll, said roller restraining the fibers within the groove substantially without pressing the tacky polymer component. 

1. Method of producing composite spun yarn which comprises: forwarding a carrier strand under tension into a groove of a rotating circumferentially grooved roll; simultaneously introducing into said groove a polymer in tacky condition and also introducing thereinto staple fibers; imparting to the three components within the groove, namely carrier strand, tacky polymer and staple fibers, a predetermined twist from an angle such that the strand in the groove is forced against the bottom of said groove while being twisted with the other components of the yarn within said groove; cooling to coagulate the polymer component of the twisted yarn; and linearly and continuously winding up the obtained twisted yarn on a collecting roll.
 2. Method according to claim 1, in which the twist is imparted by means of a false twist type spindle positioned following said groove roll roll; the yarn travelling from the grooved roll to and through said spindle at an acute angle with respect to the horizontal is thereby imparted with twist which travels back to the groove of the roll where the three components are twisted and transformed into spun yarn while being forced against the bottom of the groove.
 3. Method according to claim 1, in which the grooved roll is perforated and the fibers are held within the groove by suction from within the roll.
 4. Method according to claim 1, further comprising directing a jet of air into the groove substantially at a point where yarn is exiting therefrom.
 5. Apparatus for producing composite spun yarn which comprises: a rotatable circumferentially grooved roll; means for simultaneously introducing into the groove of said roll three components, namely a carrier strand, a tacky polymer and staple fibers; tension control means through which said carrier filament passes before being directed into the groove of said roll; a spindle following said grooved roll through which the yarn coming out of the groove is passed, said spindle imparting a twist to said yarn which is transmitted back into the groove where the three components are thus twisted into spun yarn, said spindle being positioned at an angle with respect to said grooved roll such as to impart tension and force the strand in the groove against the bottom of said groove; at least one pulling device following said spindle to maintain the yarn under positive pull; and a wind-up arrangement for linearly winding The obtained composite spun yarn on a collecting roll.
 6. Apparatus according to claim 5, wherein the means for introducing the tacky polymer comprise an extruder above the groove of said grooved roll from which the tacky polymer is extruded into said groove.
 7. Apparatus according to claim 6, wherein said means for introducing the carrier strand are adapted to direct said filament through said extruder and into the groove of said grooved roll together with the tacky polymer which is thereby coated on said strand.
 8. Apparatus according to claim 5, wherein the means for introducing the staple fibers comprise licker-in fiber delivery means by which the fibers are opened and directed into the groove of the grooved roll.
 9. Apparatus according to claim 5, wherein the grooved roll has perforations leading from the bottom of the groove towards the inside of the roll and suction means are provided within said grooved roll to produce suction in said groove from within the roll.
 10. Apparatus according to claim 5, further comprising means for directing a jet of air against the yarn exiting from the groove of said grooved roll.
 11. Apparatus according to claim 5, wherein said roll has outwardly projecting needles on at least one side of the groove, which are arranged in a converging helical circumferential path on the roll surface, said needles combing out the fibers from a direct fiber supply and conveying them into the groove of the roll.
 12. Apparatus according to claim 11, further comprising cutting blades mounted on the roll in staggered arrangement between the needles.
 13. Apparatus according to claim 11, further comprising a pressure roller mounted for pressurizing rotational movement against the groove of said roll, said roller restraining the fibers within the groove substantially without pressing the tacky polymer component.
 14. Apparatus according to claim 5, further comprising a pressure roller mounted for pressurizing rotational movement against the groove of said roll, said roller restraining the fibers within the groove substantially without pressing the tacky polymer component. 